Three-dimensional filament network packaging structure

ABSTRACT

A unitary packaging device for packaging an article includes a resilient three-dimensional web of extruded polymer monofilaments, the polymer monofilaments being heat welded at junctions to form an open network of tangled monofilament, and the resilient three-dimensional web of extruded polymer monofilaments is configured to modify the contact area between the article and an exterior container.

TECHNICAL FIELD

The present invention relates to a unitary packaging structure, and inparticular, to a dimensionally stable and resilient packaging deviceconstructed of a three-dimensional polymeric filament network.

BACKGROUND

Shipping of fragile articles requires special packaging to provide shockabsorbing to avoid damage to the fragile articles. Packaging of manydevices is typically done with an exterior container and interiorpackaging. Exterior containers are almost always made from cardboard andinterior packaging is designed to limit movement within the exteriorcontainer. The interior packaging may be made from many different typesof products, including molded cardboard, plastic bubbles, polymeric“peanuts,” or crumpled paper.

The packaging industry is currently dominated with interior packagingmade of folded cardboard that is designed to create space and providesupport within an exterior container. For example, merchandise such astelevisions and other electronics are shipped with a cardboard exteriorcontainer and a cardboard interior packaging structure. An alternativeinterior packaging structure to cardboard may be a cut or moldedpolystyrene material shaped to the contours of the merchandise beingshipped. These molded structures are typically made from expandedpolystyrene and are bulky and expensive to ship. In addition, thepolystyrene structures are not easy to recycle.

In small product packaging, such as a toy or battery package, theinterior packaging structure includes a “bubble pack” that is used tocreate a shell to hold the product within the exterior container.

With the purchasing of many products, consumers are turning more andmore to internet direct purchasing. Shipping of many of theseinternet-purchased products is based as much on the weight of theexterior container and interior packaging as on the weight of theproduct itself. Because of the high cost of shipping, smaller, lessbulky and more lightweight packaging material is desired so that thecost savings may be passed on to the consumer.

It is known in this industry how to create forms or molds for stampingout formed plastic injection molded materials. This expensive process istypically one in which the manufacturer creates a design, sends thedesign to a metal work shop, and has the profile cut into steel forinjecting plastic into the space creating an interior packagingstructure in the shape of the product to be packaged. The steel formingcan be extremely expensive to develop.

SUMMARY

In one aspect of the invention, there is provided a unitary packagingdevice for packaging an article including a resilient three-dimensionalweb of extruded polymer monofilaments, the polymer monofilaments beingheat welded at junctions to form an open network of tangledmonofilament, wherein the resilient three-dimensional web of extrudedpolymer monofilaments is configured to modify the contact area betweenthe article and an exterior container.

In one embodiment, the extruded polymer monofilaments include apolyolefin, polyamide, polyester, polyvinylhalide, polystyrene,polyvinylester, or a mixture of two or more thereof.

In one embodiment the resilient three-dimensional web of extrudedpolymer monofilaments has a plurality of protrusions. The plurality ofprotrusions may have a shape selected from among cones, truncated cones,pyramids having polygonal bases, truncated pyramids having polygonalbases, cylinders, prisms, spherical elements, and combinations of two ormore thereof. In one embodiment, the plurality of protrusions is alignedinto an array of rows.

In one embodiment, the resilient three-dimensional web of extrudedpolymer monofilaments is configured to form an article-receiving cavitysurrounded by an article-contacting surface. The article-receivingcavity may be contoured to the shape of the article.

In one embodiment, the unitary packaging device further includes acompressible layer overlaying at least a portion of the resilientthree-dimensional web of extruded polymer monofilaments. In oneembodiment, the compressible layer includes a high-loft nonwoven fabric.The compressible layer may be positioned between the article and theresilient three-dimensional web of extruded polymer monofilaments.

In one aspect of the invention there is provided a packaging systemincluding two or more of the unitary packaging devices, wherein eachunitary packaging device contacts the article.

In one embodiment, the resilient three-dimensional web of the packagingdevice has at least one pair of interlocking formations, wherein theresilient three-dimensional web is configured to be foldable onto itselfand secured in a folded position by engaging the least one pair ofinterlocking formations.

In one embodiment, the resilient three dimensional web of the packagingdevice includes top and bottom shell halves and a hinge integrallyformed with and interconnecting the top and bottom shell halves, the topand bottom shell halves cooperatively defining a cavity for containingthe article. In one embodiment, the packaging device further includes atleast one pair of interlocking formations positioned at marginalportions of the top and bottom shell halves.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a portion of the polymeric packaging deviceformed from tangled polymer filaments in accordance with the presentinvention.

FIG. 2A is a perspective view of an embodiment of the resilientthree-dimensional polymer monofilament packaging device having aplurality of protrusions.

FIGS. 2B 2H are perspective views of embodiments of the protrusions ofFIG. 2A, having a shape of cones, truncated cones, pyramids havingpolygonal bases, truncated pyramids having polygonal bases, cylinders,prisms, and spherical units, respectively.

FIG. 2I is a top view of an embodiment of the packaging device with aplurality of protrusions aligned into an array of rows.

FIG. 3 is a perspective view of an exemplary embodiment of the resilientthree-dimensional polymer monofilament packaging device configured toform an article-receiving cavity, the cavity contoured to complement theshape of the article to be packaged.

FIG. 4 is a perspective view of an embodiment of a packaging system thatincludes two resilient three-dimensional polymer monofilament membersthat cooperate to receive an article within a cavity contoured toaccommodate the shape of the article.

FIG. 5 is a side view of an embodiment of the packaging device thatincludes a compressible layer overlaying at least a portion of theresilient three-dimensional web of extruded polymer monofilaments.

FIG. 6 is a cross-sectional view of an embodiment of the resilientthree-dimensional polymer monofilament packaging device configured in afoldable clam-shell like container in an open position and having twopairs of interlocking formations.

FIGS. 7A-7C are perspective views of an exemplary embodiment of apackaging insert constructed of a resilient three-dimensional polymermonofilament material configured to receive an electronic componentwithin an article-receiving cavity, the packaging insert stabilizing theelectronic component within an outer container.

DETAILED DESCRIPTION

The present invention is directed to a resilient packaging device formedof an open network of randomly oriented polymeric filaments. Referringto FIG. 1, a portion of the packaging device is shown. The packagingdevice is constructed of a web 10 formed from a plurality of extrudedpolymer monofilaments 12. The plurality of filaments 12 are heat fusedto one another at randomly spaced points to form a three-dimensional,convoluted and mutually interconnected filamentatious body having anopen structure. Filament free voids 13 are formed within the resilientstructure, which allow the structure to absorb impacts. The polymerfilament material is preferably constructed in accordance withtechniques disclosed by, for example, U.S. Pat. Nos. 3,687,759;3,691,004; and 4,212,692, the contents of all of which are herebyincorporated by reference in their entireties.

The monofilaments 12 of web 10 may be made from any thermoplasticpolymer that provides the desired properties of strength and resiliencefor the application in which it is used. For example, the monofilaments12 may be made of a polyolefin (e.g., polyethylene, polypropylene,etc.), polyamide (e.g., Nylon), polyester, polyvinylhalide (e.g.,polyvinylchloride (PVC), polyvinylidene chloride,polyvinyltetrafluoride, polyvinyl chlorotrifluoride), polystyrene,polyvinylester (e.g., polyvinyl acetate, etc.) or a mixture of two ormore thereof. The monofilaments 12 are extruded onto a mold having thedesired structural profile to form the packaging device.

One of the benefits of the packaging device of the present invention isthe lowered cost of molding. The length of the belt or conveyer used inthe manufacturing process can be minimized through quick cooling andmade from a much less expensive process than computer-aided design (CAD)and computer numerical control (CNC) cut molds. Die cut pieces can becreated to form simple geometric patterns in the packaging device.Another beneficial characteristic is that some of the cutting can bedone in the same process as the extrusion. Instead of manufacturingcardboard pieces and die cutting them separately, the process of thepresent invention can produce the molded packaging material and in thesame process die cut the finished part. The packaging device can becorrugated in order to create strength. The packaging device can havenatural straight line molded areas so as to enhance folding ability.

The processing enhancement and the unique look of the web 10 formed froma plurality of extruded polymer monofilaments 12 makes the packagingdevice of the present invention attractive to those companies wanting tostand out. The monofilaments 12 can be any color, and can be transparentor translucent to a more typical, less expensive black filament madefrom recycled polymers. Also, the filament based materials minimize theoverall costs by lowering the quantity of material used to create thepackaging device.

Referring to FIG. 2A, in one embodiment the packaging device 18 includesa plurality of protrusions 20. The plurality of protrusions 20 modifiesthe contact area between the packaging device 18 and the packagedarticle and/or the packaging device 18 and the exterior container. Theprotrusions may extend outward from the surface of the packagingmaterial to protect the packaged article from impacts. Referring toFIGS. 2B 2H, in multiple embodiments, the plurality of protrusions 20have a shape of cones 22, truncated cones 24, pyramids having polygonalbases 26, truncated pyramids having polygonal bases 28, cylinders 30,prisms 32, or spherical units 34, respectively. The packaging device mayinclude combinations of two or more different shapes of protrusions.

Referring to FIG. 2I, in one embodiment the plurality of protrusions 20is aligned into an array of rows 36. The array of rows 36 can providesupport over a greater area of the packaged article. Moreover, eachprotrusion can be designed to contact a specific area of the article inorder to allow the exterior container to better absorb the shock of adrop. Also, each protrusion can be engineered to provide a compressiblecushion for the article by collapsing when faced with an excess load.Further, a totally randomly oriented filament process can create auniform support that transfers load from the article to the exteriorcontainer uniformly.

Referring to FIG. 3, in one embodiment the packaging device 18 isconfigured to form an article-receiving cavity 40 surrounded by anarticle-contacting surface 42. For example, the article-receiving cavitycan have a wine glass shaped configuration to accommodate the contoursof a wine glass 41 placed within the cavity 40.

Referring to FIG. 4, in one aspect a packaging system 60 includes a pairof webs. In one embodiment, a first web 62 and a second web 64 can bemirror images of each other if the article 41 to be placed within thearticle-receiving cavity has a symmetrical shape. The packaging systemcan include a pair of webs configured to cooperatively define anarticle-receiving cavity 40 a, 40 b for closely retaining a symmetricalor non-symmetrical article to be packaged. The pair of webs supports thearticle toward the center of the package.

Referring to FIG. 5, in one embodiment a compressible layer 50 overliesat least a portion of the web 10 and is positioned between a packagedarticle 52 and the web 10. The compressible layer 50 may be manufacturedfrom an ultra lightweight fabric that is “cotton” like in nature. Thefabric 50 may be designed to compress into the web 10 creating a smallcushion under the plurality of extruded polymer monofilaments 12 andpressing back toward the web 10. The fabric 50 can be made from apolymer based filament in a manufacturing process known as carding. Incarding, chopped filaments are combed in one direction and then heatedand needled to make them combine into a monolithic mat. In the needlingoperation, sharp, thin metal prongs (i.e., needles) are driven in andout of the filaments to entangle them together. This process of carding,heating, and needling allows for the material to achieve a high loft orthick fabric quality.

Referring to FIG. 6, in one embodiment the packaging device 80 formedfrom a plurality of extruded polymer monofilaments 12 has a clam shellconfiguration, including a bottom shell half 70 and a top shell half 74that are connected by connection section 72. Packaging device 80 isillustrated in the unfolded or open position. The bottom shell half 70has an outer lip 92 that includes a downwardly facing locking dome 76B.The top shell half 74 has an outer lip 94 that includes an upwardlyfacing locking dome 76A, which is complementary to locking dome 76B. Theconnection section 72, which acts as a flexible hinge for the packagingdevice 80, includes a pair of complementary interlocking domes 78A and78B positioned on opposing sides of fold line 82. Arrow 90 indicates thefold direction of the packaging device 80. Upon folding the packagingdevice 80 along fold line 82 in the folding direction, dome 78A engagesdome 78B and dome 76A on the outer lip 94 of the top shell half engagesdome 76B on the outer lip 92 on the bottom shell half 70 to secure thepackaging device 80 in a closed position.

Referring to FIGS. 7A to 7C, in one embodiment the packaging device 100is a container insert for packaging an electronic component 104, such asa computer monitor or flat screen television. The packaging device 100includes an article receiving cavity 102 that is configured tocomplement the shape of the electronic component 104. The outerdimensions of packaging device 100, i.e., the length (L), width (W) andheight (H), are matched to the dimensions of an outer container 106. Theelectronic component 104 is nested in the article-receiving cavity 102,and the packaging device 100 is nested in the outer container 106. Thethree-dimensional polymeric filament network of the packaging device 100acts as a shock absorber to protect the electronic component 104 withinthe outer container 106 during transport and storage.

Although the invention has been shown and described with reference tocertain exemplary embodiments, it is understood that equivalents andmodifications may occur to others skilled in the art upon reading andunderstanding the specification. The present invention is intended toinclude all such equivalents and modifications as they come within thescope of the following claims.

1. A unitary packaging device for packaging an article comprising: aresilient three-dimensional web of extruded polymer monofilaments, thepolymer monofilaments being heat welded at junctions to form an opennetwork of tangled monofilament, wherein the resilient three-dimensionalweb of extruded polymer monofilaments is configured to modify thecontact area between the article and an exterior container.
 2. Theunitary packaging device of claim 1, wherein the extruded polymermonofilaments comprise a polyolefin, polyimide, polyester,polyvinylhalide, polystyrene, polyvinylester, or a mixture of two ormore thereof.
 3. The unitary packaging device of claim 1, wherein theresilient three-dimensional web of extruded polymer monofilaments has aplurality of protrusions.
 4. The unitary packaging device of claim 3,wherein the plurality of protrusions have a shape selected from amongcones, truncated cones, pyramids having polygonal bases, truncatedpyramids having polygonal bases, cylinders, prisms, spherical elements,and combinations of two or more thereof.
 5. The unitary packaging deviceof claim 4, wherein the plurality of protrusions is aligned into anarray of rows.
 6. The unitary packaging device of claim 1, wherein theresilient three-dimensional web of extruded polymer monofilaments isconfigured to form an article-receiving cavity surrounded by anarticle-contacting surface.
 7. The unitary packaging device of claim 6,wherein the article-receiving cavity is contoured to the shape of thearticle.
 8. The unitary packaging device of claim 1, further comprisinga compressible layer overlaying at least a portion of the resilientthree-dimensional web of extruded polymer monofilaments.
 9. The unitarypackaging device of claim 8, wherein the compressible layer comprises ahigh-loft nonwoven fabric.
 10. The unitary packaging device of claim 8,wherein the compressible layer is positioned between the article and theresilient three-dimensional web of extruded polymer monofilaments.
 11. Apackaging system comprising two or more of the unitary packaging devicesof claim 1, wherein each unitary packaging device contacts the article.12. A unitary packaging device of claim 1, wherein the resilientthree-dimensional web has at least one pair of interlocking formations,wherein the resilient three-dimensional web is configured to be foldableonto itself and secured in a folded position by engaging the least onepair of interlocking formations.
 13. The unitary packaging device ofclaim 1, wherein the resilient three dimensional web comprises top andbottom shell halves and a hinge integrally formed with andinterconnecting the top and bottom shell halves, the top and bottomshell halves cooperatively defining a cavity for containing the article.14. The unitary packaging device of claim 13, further comprising atleast one pair of interlocking formations positioned at marginalportions of the top and bottom shell halves.